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Heat and Electricity From Waste PDF
Heat and Electricity From Waste PDF
SYSAV
Box 50344, SE-202 13 Malmö, Sweden
Phone +46 40-635 18 00
Fax +46 40-635 18 10
www.sysav.se
epost@sysav.se
Waste as fuel
Sysav’s waste-to-energy plant has four boilers. The two oldest came into
operation in 1973. They are hot-water boilers which produce district
heating. Both the boilers and the system for cleaning flue gases have
been reconditioned and developed in line with heightened demands on
waste combustion. The two newest boilers are steam boilers and
generate both electricity and district heating. They came online in 2003
and 2008 respectively.
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How the plant works
ENERGY RECOVERY:
8 1. Waste bunker
7
2. Travelling crane
3. Feed chute
6 A 4. Boiler
2 5. Slag outlet
6. Superheaters
9 13
7. Turbine
3
8. Generator
9. Condenser
4 10. Heat pumps
1 11. Direct condensation
5 12. Economiser
13. District heating and
electricity customers
J
FLUE GAS CLEANING AND
D E WASTE WATER TREATMENT:
L B F A. Electrostatic precipitator
G I K B. Heat exchanger
C H C. Quench
D. Acid scrubber
M
E. Basic scrubber
Q F. Condensing scrubber
12 G. Electroventuri filter
N O 10 H. Heat exchanger
P
11 I. Preheater
J. Catalyst
K. Stack
L. Neutralisation, precipitation
and flocculation
M. Decanter
N. Ash silo
O. Sludge silo
P. Filter press
Q. Sand and carbon filters
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Energy from waste – step by step
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Approximately 1,400,000 MWh of From water to steam The district heating water is heated to between
district heating and 250,000 MWh The flue gases formed during the combustion process 80 and 115°C depending on the outdoor temperature
of electricity are produced a year maintain a temperature of at least 850°C. They pass and is used to heat homes and other buildings.
in Sysav’s waste-to-energy plant. three vertical empty ducts with tubes on the walls
Some of the electricity is used where the temperature is high. The function of the Direct condensation and heat pumps harness
internally within Sysav, partly in heat the remaining energy
empty ducts is to achieve complete combustion of
pumps to produce district heating.
the flue gases. The flue gases then heat the boiler water When the district heating water returns to the plant it
The rest is delivered to the power
circulating in tubes. The horizontal part of the boiler has a temperature of 40-60°C. Through direct
distribution grid.
comprises convection tubes and super-heaters. The condensation, heat pumps and flue gas heat
boiler water reaches its highest energy value here at exchangers, heat is extracted from moisture in the fuel
a temperature of 400°C and a pressure of 40 bar. which has been turned into steam in the condensing
scrubber.
From steam to electricity… The recovered heat energy increases the temperature
The hot high-pressure steam from the boiler is directed of the district heating water with 5-10°C before it
to the turbine which drives a generator. Some of the enters the condenser. The building’s waste heat is also
electricity produced is used in the plant, while the rest collected in a waterborne system and is extracted
goes onto the power distribution grid. through heat pumps.
The heat pumps are powered by some of the
…and district heating electricity produced in the plant. The flue gas is
Once the steam has passed through the turbine, it is additionally cooled before it is let out through the stack,
directed to a condenser where it is used to heat and the heat is recovered through an economiser. In
district heating water. If the turbine is not in operation total, the heat recovery in the flue gas cleaning plant is
the steam can be directed straight to the condenser. equivalent to an effect of 20-25 MW per line.
In the condenser, which is a large heat exchanger,
the steam becomes water (condensate) once it has
transferred its heat to the district heating water. The Boiler water in
condensate is then pumped via a feed-water tank back
Generator
into the boiler’s water/steam system.
Turbine
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Washed with water
The wet part of the cleaning process comprises three flue gases come into contact with the water spray,
scrubbers – two cleaning scrubbers and a condensing contaminants are washed away. Different cleansing
scrubber – where various substances are washed away chemicals are added along with the water in the three
one by one. Before the gas enters the wet part of the scrubbers to bring about a reaction with different
cleaning process, the temperature is decreased to substances in the flue gases. The washing water is
60-70°C using heat exchangers and cooling water. In replaced at intervals and cleaned in a special water
the scrubbers, the flue gases are washed with water, treatment plant.
which is sprayed through ceramic nozzles. When the
Approximately 15 m3 of water
an hour normally pass through
the scrubbers and the subse-
quent water treatment process. Flue gas
Rökgas
For the majority of the year, in
IN
the water comes only from the
condensing scrubber, i.e. from
the fuel.
Water
Vatten
in
IN
Flue gas
Rökgas
out
UT
Water
Vatten
out
UT
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Stopping dust with a wet electrostatic Catalyst in the final stage of cleaning
precipitator The final stage of the flue gas cleaning process comprises
The penultimate cleaning stage for the flue gases a catalyst. In the catalyst, the flue gases pass through a
consists of an electroventuri filter, which works in fine ceramic material and ammonia water is injected.
almost the same way as an electrostatic precipitator, The nitrogen oxide reacts with the ammonia, whereby
but in a wet environment. This is where any remaining it is reduced to nitrogen and steam. Finally the flue
dust in the flue gases is removed. The electroventuri gases are released, using a flue gas fan, out through
filter comprises 24 pipes, which narrow considerably the 100 metre tall stack.
to increase the flow rate of the flue gases. The dust
particles are negatively charged by an electrode and
absorbed by positively charged water spray in the
lower part of the filter.
The water is then directed to the water treatment
plant via the acid scrubber.
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The water is cleaned too Water treatment:
The flue gases have now been cleaned, and the
1. NEUTRALISATION TANK 1
contaminants washed out of the gases are now in the
water from the scrubbers and the electroventuri filter. 2. NEUTRALISATION TANK 2
Before the cleaning process can be considered
complete, the water must be cleaned as well. 3. PRECIPITATION TANK
By adding various chemicals, heavy metals and
4. FLOCCULATION TANK
other contaminants are precipitated in a series of tanks
where they form a sediment and are concentrated 5. DECANTER
into a sludge.
6. FINAL NEUTRALISATION TANK
8. ASH SILO
9. SLUDGE SILO
1 2 3 4
6
5
8 9
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ENERGY RECOVERY:
1. Waste bunker
8
2. Boiler
3. Economiser
4. Bag filter
5. Four-stage scrubber
6. Water treatment
7. Ash silo
8 8. Heat exchanger for district
heating
4
3 5
2
Boiler evolution
The hot-water boilers from
1973 have been progressively
reconditioned and developed
in line with heightened demands
on waste combustion. In 1981
1 the electrostatic precipitator
was supplemented by dry flue
gas cleaning comprising lime
reactors and a bag filter, and
nitrogen oxide reduction was
added to the flue gas cleaning
process in 1992. In 2005 the hot-
water boilers were recondi-
tioned and supplemented with
wet flue gas cleaning. When the
first steam boiler was built,
7
operation and monitoring were
6
moved to a central control
room in a superstructure
between the old and new parts
of the waste-to-energy plant.
The oldest part of Sysav’s waste-to-energy plant came with both dry and wet cleaning. First ammonia water is Four-stage wet cleaning The water is cleaned and led off
into operation in 1973. It comprises two hot-water sprayed directly into the boiler to reduce nitrogen Wet cleaning consists of a four-stage scrubber. The first The contaminated water from the first two scrubbing
boilers, each with a combustion capacity of 100,000 oxides. Acidic substances are then neutralised by two stages remove chlorides, hydrogen fluoride, metals stages is led back to the boilers. The water from stage
tonnes of waste a year. adding slaked lime to the flue gases. and ammonia. The third stage primarily removes sulphur three and the condensation stage is cleaned in a
dioxide. In the final step, the condensation stage, the separate treatment process. This comprises a bag filter
District heating production Bag filter removes dust water in the flue gases is condensed. Each stage involves for particle removal, two ion exchangers and two
The water in the hot-water boilers is heated to 150°C. A textile bag filter separates lime and dust particles, a bed of carbon-saturated filling material which absorbs mercury ion exchangers for metal removal.
The flue gases are led to an economiser where further the result being virtually complete removal of primarily any dioxins and increase the contact surface between The cleaned water is then led out into the sea.
heat is recovered. The heat in the boiler water is passed dust and metals. The bag filter is essentially made up of water and contaminants, ensuring a good cleaning
on to the district heating network via two heat exchangers. long, suspended tubes. The flue gas, which is pressed in effect. The heat energy in the condensate water from
from beneath the filter, goes into the tubes, while the the final scrubbing stage is harnessed and transferred
Dry and wet cleaning of the flue gases dust remains on the outside. The cleaned flue gases are to the district heating network via a heat exchanger.
The flue gas cleaning system comprises several stages then sucked into the wet cleaning process by a fan.
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Residues, environment and monitoring
Energy production from waste gives rise to a number of Monitoring and the environment
types of residue. Roughly 15-20% of the waste by weight All processes at Sysav’s waste-to-energy plant are
remains in the shape of slag. The slag is transported to continuously monitored from the central control
the nearby waste site at Spillepeng. At the site, scrap room. Round the clock there are operating personnel
iron and other metals are separated for recycling and monitoring combustion, the production of steam,
the remaining slag gravel can be used as hard core or electricity and district heating, and especially the
aggregate in construction. cleaning and treatment processes. All important
emissions are measured, recorded and monitored
Ash, sludge and gypsum carefully to ensure the operation meets the strict
Dry ash is captured in boilers, electrostatic precipitators environmental requirements. The control room is staffed
and bag filters. The contents of this ash include lime and Measurement and registration take place with round the clock.
lime-bound contaminants, as well as metals. Roughly 3 kg permanently installed instruments which show data
of ash is produced from the combustion of 100 kg of both locally and in the control room. There are set
waste. Due to its chemical properties, the ash needs to templates for daily and monthly parameter reports,
go into environmentally safe final storage. The ash has and these are printed out from a special environmental
been dealt with in different ways over the years, for computer.
example recycling by neutralisation of waste acids at
Langøya, Norway. Permits and reporting
Because the flue gases are cleaned with water, The Environmental Court in Växjö has licensed Sysav
there is also a wet residue: sludge. The sludge contains to use 550,000 tonnes of waste a year at its waste-to-
contaminants such as heavy metals, and like the ash energy plant. Every year Sysav submits an environmental Each boiler is shut down once a year
these need safe final storage. They are deposited in a report outlining its operations, as well as environmental for overhaul and repairs. This is done
special cell at the nearby Spillepeng landfill site. controls and inspections carried out by the supervisory during the summer when there is
In one of the scrubbing stages on lines 3 and 4, authority. All other reporting regarding nonconformities the least demand for district heating.
sulphur is removed from the flue gases in the form in the operation are also sent to the supervisory
of gypsum slurry. The slurry is dewatered in a vacuum authority.
band filter, and the dried gypsum is also sent to the
landfill site for final storage.
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Waste to energy
– an important complement
Waste to energy is an important complement to other waste treatment.
Using waste as a fuel is a way of using the energy bound up in the mate-
rial. Three tonnes of waste can produce around the same amount of
energy as one tonne of oil. Waste can also largely be considered a
biofuel, as approximately 85% of the waste by weight is comprised of
renewable material. Using waste as a fuel contributes to lower carbon
dioxide emissions if it replaces the use of fossil fuels. Optimised running
and an advanced process for cleaning the flue gas minimise the operation’s
impact on the environment, while at the same time waste is converted
into valuable energy.
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